Generally speaking, devices that require larger current (amp) loads demand larger diameter wire, measured in American Wire Gauge (AWG). Wire size (diameter) is another big consideration. (Image/OnAllCylinders) Understanding American Wire Gauge (AWG) For larger jobs, like battery cables, you might want to use an impact crimper, like the one featured here: How to Use the Moroso Impact Wire Crimping Tool This is our trusty vintage Vaco manual crimper/stripper/cutter workhorse, note the specific die marks for 22-14 AWG and 12-10 AWG wire. In this article, were talking about handheld crimpers, well suited to the smaller diameter wires (about 20 to 10 gauge) that are common in home and auto electrical accessory systems. The good news is, plenty of tool manufacturers make versatile crimpers for installing a wide range of basic terminals like the ones pictured above. So assess what kind of connector or terminal you’re crimping first, before buying a wire crimper. Sometimes the connectors themselves require other specialized tools, here’s a good example: How to Assemble Weatherproof Deutsch DT Connectors The tool on the left is for RF coaxial connectors, the one on the right can handle the traditional wire terminals and connectors seen in the organizer case here. As an example, the crimpers for engine ignition wires are dramatically different from the crimpers made for installing TV/video connectors onto coaxial cable. For starters, crimpers are often designed for a specific wire gauge or terminal/connector type. (Image/OnAllCylinders) Pick a Crimper Designed for the Specific Taskīut there are a few things to consider when buying a wire crimping tool. We won’t spend time on assembling ignition wires here, because we’ve already created an in-depth tutorial: How to Make Custom Spark Plug Wire Sets A crimp conector is basically squeezed onto the wire, and though opinions differ, it is considered the optimal connection type for automotive use. So whether you’re making spark plug wires or installing a bangin’ stereo, a purpose-built wire crimper is a smart way to ensure the job gets done right. Using the improper crimping tool can crush and distort the connector, tear the wire insulation, or cut the wire conductor inside-and that’s how electrical gremlins are born. (Image/OnAllCylinders)īut a lot of folks often get-by using an ordinary pair of pliers to apply the crimp, which isn’t a good alternative. Many connectors also integrate a heat shrink sleeve that’s activated by a heat gun to insulate and grip the wire too. But if you’re handy with a soldering iron, you’ll probably enjoy this article: The Lineman’s Splice: How to Make Reliable Electrical Connections in Your Vehicle’s Wiring Harness To install a typical crimp connector like this, you simply strip away the wire insulation, insert the exposed conductor into the crimp barrel of the connector/terminal, and then squeeze the tool around the crimp to make the connection secure. What is a Wire Crimp Tool?Ī good Wire Crimping Tool is downright essential for making proper electrical crimp connections and installing terminals, both in a vehicle and around the house.Ī crimp tool’s function is delightfully simple: It essentially squeezes the metal collar of a connector around the wire conductor to create a strong, durable electrical connection (keep scrolling to see a picture of it in action).Ĭrimping is an alternative to soldering. And while professional-spec crimping tools can easily reach $100, for occasional electrical wire crimping jobs, you’ll have no problem finding a quality wire crimper for under 30 bucks. This article was originally part of our Tools Under 30 Dollars Gift Guide Series because a lot of gearheads don’t have a dedicated set of wire crimpers, often relying on other tools (like pliers) to do the job-with varying success.
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